Technical manual 911 GT3 Cup (991) MY 2016 Preface Preface This document should give you the opportunity to look up data, settings, und operating regulations, and to facilitate maintenance or repair of the vehicle. We wish you many sporting successes with your 911 GT3 Cup (991). Customer Sport Dr. Ing. h.c. F. Porsche Inc. Motorsport Sales 911 GT3 Cup (991) Version: 15.01.2016 MY 2016 1 Competition Vehicle 911 GT3 Cup (991) Model 2016 Preface The design of this vehicle is specially configured for use in one-make cup competitions. For understandable reasons, it cannot therefore be assumed that the standards set by our production vehicles are relevant for the car body design. Porsche assumes no responsibility for compliance with regulations. The vehicle is not approved for use on public roads and does not comply with the German Road Traffic Licensing Regulations. Pictures, descriptions, and schematic drawings are used solely for illustrating the text. We assume no responsibility for the completeness and conformity of the contents with the prevailing sporting codes. Due to the constant improvement of our products and the related documentation at the time of your purchase, a new version of this technical manual could be available. The latest Version is always accessible at the "Porsche Motorsport race car service information" database (PMRSI), and can be downloaded on the following homepage. https://motorsport.porsche.com 911 GT3 Cup (991) 2 MY 2016 Version: 15.01.2016 Contact International One-make Cup Series Preface Assistent Ms. Nicole Nagel Tel. + 49 (0) 711 911 84900 Mr. Tobias Hütter Tel. +49 (0)711 911 82616 Fax. + 49 (0) 711 911 88920 Technical Support Mr. Christoph Werner Tel. + 49 (0) 711 911 82690 Fax. + 49 (0) 711 911 89535 Porsche Mobil 1 Mr. Oliver Schwab Tel. + 49 (0) 711 911 84042 Supercup Assistent Ms. Olivia Wegner Tel. + 49 (0) 711 911 84096 Fax. + 49 (0) 711 911 82920 Technical Support Mr. Maximilian Müller Tel. +49 (0)711 911 86183 Fax. + 49 (0) 711 911 89535 Porsche Carrera Cup Ms. Andrea Hagenbach Tel. + 49 (0) 711 911 84041 Germany Assistent Mr. Marco Vierkötter Tel. + 49 (0) 711 911 84074 Fax. + 49 (0) 711 911 82920 Technical Support Mr. Maximilian Müller Tel. +49 (0)711 911 86183 Fax. + 49 (0) 711 911 89535 Sports Divisions Sales Mr. Karlheinz Kienle Tel. + 49 (0) 711 911 82923 Part order [email protected] Consulting & sale Mr. Klaus Lenzner Tel. + 49 (0) 711 911 82423 Mr. Christian Müller Tel. + 49 (0) 711 911 89175 Mr. Salvatore Scozzaro Tel. + 49 (0) 711 911 83738 Mr. Robert Hirrig Tel. +49 (0)711 911 82687 Mr. Jens Lange Tel. +49 (0)711 911 85041 Mr. Mario Heinzel Tel. +49 (0)711 911 87108 Fax. + 49 (0) 711 911 82808 911 GT3 Cup (991) Version: 15.01.2016 MY 2016 3 Contents Preface Preface 1 1 Engine 13 1.1 General 13 1.2 Specifications 14 1.3 Engine lubrication 15 1.3.1 Engine oil circuit 16 1.3.2 Oil level measurement 17 1.3.3 Refilling engine oil 17 1.3.4 Engine oil 17 1.4 Engine cooling system 18 1.4.1 Schematic diagram 18 1.4.2 Thermostat 18 1.4.3 Coolant 19 1.4.4 Filling the cooling system 19 1.4.5 Races at low temperatures 19 1.5 Intake system 20 1.5.1 Resonance flaps 20 1.5.2 Throttle 21 1.6 Work on the engine 22 1.6.1 Cylinder head installation 22 1.6.2 Flywheel tightening instructions 23 1.6.3 Setting the valve timing 23 1.6.4 Removing and installing the crankshaft seal – pulley side 24 1.6.5 Removing and installing the crankshaft seal – flywheel side 29 1.7 Engine tightening torque overview 36 1.8 Exhaust system 38 1.9 Fixation pre-silencer 39 911 GT3 Cup (991) 4 MY 2016 Version: 15.01.2016 1.10 Engine run time 40 1.10.1 Behavior when exceeding the maximum speed 40 Preface 2 Powertrain 41 2.1 General 41 2.2 Clutch 42 2.2.1 Installation instructions 42 2.2.2 Clutch wear 43 2.2.3 Fluid for clutch actuation 43 2.2.4 Central release mechanism 44 2.3 Sequential six-speed gearbox 45 2.3.1 Overview 45 2.3.2 Technical specifications 46 2.3.3 Gear set 47 2.3.4 Drive 50 2.3.5 Oil circuit 52 2.4 Gear shift mechanism 53 2.4.1 Gear shifting 54 2.4.2 Gear recognition 56 2.4.3 „Emergency gearbox“ switch 56 2.4.4 Maintenance 57 2.5 Drive shafts 58 2.5.1 Tightening instructions 58 2.6 Gearbox run time 59 2.7 Gearbox tightening torques 59 911 GT3 Cup (991) Version: 15.01.2016 MY 2016 5 2.8 Transmission dismantling 61 2.8.1 Dismantling of hang-on parts 61 Preface 2.8.2 Gear housing dismantling 62 2.8.3 Gear set removal 63 2.8.4 Dismantling the shift drum 64 2.8.5 Dismantling the locking sleeve 64 2.8.6 Oil supply 65 2.8.7 Cross shaft dismantling 66 2.8.8 Pinion shaft dismantling 69 2.8.9 Differential removal 70 2.8.10 Central clutch operator removal 71 2.8.11 Connecting shaft dismantling 71 2.8.12 Drive shaft dismantling 72 2.8.13 Bearing dismantling 73 2.9 Transmission assembly 75 2.9.1 Gearbox housing pre-assembly 75 2.9.2 Gear housing pre-assembly 86 2.9.3 Differential lid pre-assembly 92 2.9.4 Pinion shaft bearing assembly 93 2.9.5 Pinion shaft 94 2.9.6 Pinion shaft position adjustment 96 2.9.7 Assembly of gear sets 98 2.9.8 Vormontage Schaltwalze 104 2.9.9 Oil pump assembly 105 2.9.10 Reverse idler gear 106 2.9.11 Locking sleeve 107 2.9.12 Shift rod and shift forks 108 2.9.13 Suction tube assembly 109 2.9.14 Central clutch operator assembly 111 2.9.15 Cutted gear housing assembly 111 2.9.16 Determining cross shaft bearing adjusting disk Q1 113 2.9.17 Cross shaft setup 114 2.9.18 Cross shaft assembly 115 2.9.19 Differential setup 119 2.9.20 Gear housing assembly 126 2.10 Overview gearbox settings 132 911 GT3 Cup (991) 6 MY 2016 Version: 15.01.2016 3 Chassis 133 Preface 3.1 General 133 3.1.1 Wheel bearing 134 3.1.2 Wheel hub 135 3.1.3 Wheel nut 136 3.1.4 Locking piece 137 3.2 Front axle 138 3.2.1 Front axle cross member 139 3.2.2 Front axle transverse control arm 140 3.2.3 Longitudinal control arm 141 3.2.4 Front axle wheel mount 142 3.2.5 Front axle shock absorber 143 3.2.6 Front axle anti-roll bar 144 3.3 Rear axle 146 3.3.1 Rear axle control arm and tie rod 147 3.3.2 Fixation trailing arm bracket 148 3.3.3 Rear axle transverse control arm 149 3.3.4 Rear axle wheel mount 150 3.3.5 Rear axle shock absorber 151 3.3.6 Rear axle anti-roll bar 152 3.3.7 Rear axle side part 154 3.4 Wheel alignment 154 3.4.1 Preparatory measures 155 3.4.2 Vehicle ride height measuring points 156 3.5 Steering system 157 3.5.1 Bleeding the steering system 159 3.6 Rims and tire 160 3.6.1 Rim 160 3.6.2 Tires 160 3.7 Brake system 161 3.7.1 General 161 3.7.2 Front axle brake 163 3.7.3 Rear axle brake 164 3.7.4 Master cylinders 165 3.7.5 Changing the brake fluid 166 911 GT3 Cup (991) Version: 15.01.2016 MY 2016 7 3.8 Brake pressure distribution 167 3.8.1 Balance beam basic setting 168 Preface 3.8.2 Calculating the brake power 170 3.9 Balance bar replacement kit 171 3.9.1 Replacing the trunnion 171 3.9.2 Replacing the balance bar 171 3.10 Performance setup 172 4 Bodywork 173 4.1 General 173 4.2 Front and side view 174 4.3 Rear view 176 4.4 Body shell 177 4.4.1 General 177 4.4.2 Weight distribution 179 4.4.3 Weight percentage of the Body -in-White 179 4.4.4 Body aluminum parts 180 4.4.5 Body features 181 4.4.6 Body steel parts 182 4.4.7 Materials overview 183 4.4.8 Roll cage 184 4.4.9 Recovery device 185 4.5 Aerodynamics 186 4.5.1 General 186 4.5.2 Rear wing 186 4.5.3 Additional aerodynamic improvements 186 4.6 Exterior mirrors 187 4.7 Roof 187 4.8 Air jack system 188 4.9 Doors 190 911 GT3 Cup (991) 8 MY 2016 Version: 15.01.2016 4.10 Trunk and engine lid 190 4.10.1 Trunk lid 190 4.10.2 Engine lid 190 Preface 4.11 Windows 191 4.11.1 Installing and removing the windshield 191 4.11.2 Preparing the window cutout for installation 195 4.11.3 Preparing the windshield for installation 196 4.11.4 Installing the windshield 197 4.12 Fenders 199 4.13 Wheel cover 199 4.14 Fuel system 200 4.14.1 Fuel 201 4.14.2 Defueling 201 4.14.3 Tank installation 202 4.15 Repairing the body 202 4.15.1 Repairing the front section 203 4.15.2 Replacing the front strut mount 217 4.15.3 Repairing the rear end 225 4.16 Thread repair kit 229 4.16.1 Thread repair of chassis bolt connections 231 4.17 Installing roof assembly 247 5 Interior 249 5.1 General 249 5.2 Drivers safety 250 5.2.1 Seat 250 5.2.2 Seat rail tightening torques 251 5.2.3 Bucket seat tightening torques 252 5.2.4 Padding system 253 5.3 Steering wheel 254 5.4 Cockpit ventilation 255 911 GT3 Cup (991) Version: 15.01.2016 MY 2016 9 6 Electrical system 257 Preface 6.1 General 257 6.2 Power supply 257 6.2.1 Battery 257 6.2.2 Generator 257 6.2.3 Battery master switch 258 6.3 Electrical system protection 259 6.3.1 Electrical system control unit IPS32 259 6.3.2 Fuse holder hydraulic pump 260 6.4 DME engine electronics 260 6.4.1 DME control unit 261 6.4.2 DME diagnosis 262 6.4.3 Carburation 262 6.4.4 Ignition system 262 6.5 Sensors 263 6.5.1 Sensor rated values 264 6.5.2 Optional sensors 265 6.6 ICD Display 266 6.6.1 General 266 6.6.2 Race page 268 6.6.3 Practice page 271 6.6.4 Warmup page 273 6.6.5 Vitals page 274 6.6.6 Pedals page 277 6.6.7 Additional information 279 6.7 Lights 285 6.8 Data bus system 286 6.9 Wiring harness 287 6.10 Ground connection roof antenna 287 6.11 Fire extinguisher 288 6.11.1 Testing the trigger switch 289 6.11.2 Battery change 289 911 GT3 Cup (991) 10 MY 2016 Version: 15.01.2016 6.12 Driver Control Systems 290 6.12.1 Steering wheel 290 6.12.2 Center console 291 Preface 6.12.3 Windscreen wiper 292 6.12.4 Interior fan switch 292 7 Maintenance 293 7.1 Engine 293 7.1.1 Oil level measurement using the dipstick 293 7.1.2 Oil level measurement with display 294 7.1.3 Changing the engine